Non-uniform steerer tube or fork leg

ABSTRACT

A fork assembly including a steerer tube and a crown, wherein the steerer tube is fixedly aligned to the crown in a predefined orientation at a time of manufacture.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part and claims the benefit of andclaims priority to the U.S. patent application Ser. No. 16/659,272 filedon Oct. 21, 2019, entitled “NON-UNIFORM STEERER TUBE OR FORK LEG” byWilliam O. Brown, IV et al., assigned to the assignee of the presentapplication, and is hereby incorporated by reference in its entirety.

U.S. patent application Ser. No. 16/659,272 filed on Oct. 21, 2019claims the benefit of and claims priority to the U.S. Provisional PatentApplication No. 62/751,929 filed on Oct. 29, 2018, entitled “NON-UNIFORMSTEERER TUBE OR FORK LEG” by William O. Brown, IV et al., assigned tothe assignee of the present application, and is hereby incorporated byreference in its entirety.

FIELD OF THE INVENTION

Embodiments of the present technology relate generally to a steerer tubeand/or a fork leg.

BACKGROUND

Conventionally a steerer tube is coupled with a fork or other mechanismto enable a user to steer a vehicle such as, but not limited to, abicycle, a motorcycle, and the like. More specifically, the steerer tubeis typically coupled to handlebars using a stem. As a result, movementof the handlebars by a user results in rotation of the steerer tube.Further, as the steerer tube is also ultimately coupled to, typically,the front wheel, rotation of the steerer tube results in turning of thewheel (i.e., non-axial movement of the wheel). Hence, as the steerer isultimately coupled to the front wheel and to the handlebars, the steerertube can be subjected to significant forces, torques, vibrations, andthe like. Similarly, the fork (or fork legs) of the vehicle can besubjected to significant forces, torques, vibrations, and the like.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present invention are illustrated by way of example, andnot by way of limitation, in the accompanying drawings, wherein:

FIG. 1 is a perspective view of a non-uniform steerer tube, inaccordance with an embodiment of the present invention.

FIG. 2 is a cross-sectional view of the non-uniform steerer tube of FIG.1, in accordance with an embodiment of the present invention.

FIG. 3 is a perspective view of the non-uniform steerer tube of FIG. 1taken from an angle different from that of FIG. 1, in accordance with anembodiment of the present invention.

FIGS. 4A-4C are side-sectional views of one embodiment of a non-uniformsteerer tube, in accordance with an embodiment of the present invention.

FIGS. 5A-5C are side-sectional views of another embodiment of anon-uniform steerer tube, in accordance with an embodiment of thepresent invention.

FIGS. 6A-6C are perspective views of a non-uniform steerer tube locatedon a bicycle, in accordance with an embodiment of the present invention.

FIG. 7 is a perspective view of a steerer tube and crown, in accordancewith an embodiment of the present invention.

FIG. 8 is a perspective view of a steerer tube coupled to the crown thatincludes an example alignment mark, in accordance with an embodiment ofthe present invention.

FIG. 9 is a perspective view of the steerer tube coupled to the crownthat includes an alignment mark along a portion of the length of thesteerer tube, in accordance with an embodiment of the present invention.

FIG. 10A is a perspective view of a stem with an alignment feature, inaccordance with an embodiment of the present invention.

FIG. 10B is a perspective view of a stem with an alignment featurealigned with the alignment feature of the steerer tube, in accordancewith an embodiment of the present invention.

FIG. 11A is a perspective view of the steerer tube coupled to a crownthat includes an alignment feature along a portion of the length ofsteerer tube taken from an angle different from that of FIG. 9, inaccordance with an embodiment of the present invention.

FIG. 11B is a perspective view of the stem with a female alignmentfeature aligned with a female alignment feature of the steerer tube andusing a pin to align the two features, in accordance with an embodiment.

FIG. 12 is a perspective view of the stem coupled with the steerer tubethat is coupled with the fork assembly, in accordance with anembodiment.

FIG. 13A is a perspective view of a keyed headset spacer with twoalignment features, in accordance with an embodiment.

FIG. 13B is a perspective view of the stem installed onto a steerer tubewith a female alignment feature, in accordance with an embodiment.

FIG. 13C is a perspective view the keyed headset spacer of FIG. 13Aaligning the stem and the steerer tube of FIG. 13B, in accordance withan embodiment.

FIG. 14A is a perspective view of a top cap with two alignment features,in accordance with an embodiment.

FIG. 14B is a perspective view of the stem installed onto a steerer tubein conjunction with the keyed headset spacer, in accordance with anembodiment.

FIG. 14C is a perspective view the top cap of FIG. 14A acting inconjunction with the keyed headset spacer to aligning the stem and thesteerer tube of FIG. 14B, in accordance with an embodiment.

FIG. 14D is a cross-sectional view of the top cap acting in conjunctionwith the keyed headset spacer to align the stem and the steerer tube ofFIG. 14C, in accordance with an embodiment of the present invention.

The drawings referred to in this description should be understood as notbeing drawn to scale except if specifically noted.

DESCRIPTION OF EMBODIMENTS

The detailed description set forth below in connection with the appendeddrawings is intended as a description of various embodiments of thepresent invention and is not intended to represent the only embodimentsin which the present invention is to be practiced. Each embodimentdescribed in this disclosure is provided merely as an example orillustration of the present invention, and should not necessarily beconstrued as preferred or advantageous over other embodiments. In someinstances, well known methods, procedures, objects, and circuits havenot been described in detail as not to unnecessarily obscure aspects ofthe present disclosure.

As stated above, in some vehicles, a steerer tube is ultimately coupledto a wheel of a vehicle. Similarly, in some vehicles, a fork leg of afork is ultimately coupled to a vehicle. For purposes of brevity andclarity, the following discussion will refer to embodiments of thepresent invention corresponding to a steerer tube. It should be noted,however, that various embodiments of the present invention are wellsuited for use in an upper fork leg, a lower fork leg, or concurrentlyin both of the upper fork leg and the lower fork leg, or any combinationof fork legs in conjunction also with use in a steerer tube. That said,for purposes of brevity and clarity only, and not to be interpreted as alimitation, the following discussion will refer to embodiments of theinvention pertaining to a steerer tube.

As will be described in detail below, embodiments of the presentinvention provide a non-uniform steerer tube. Referring now to FIG. 1, aperspective view is shown of a non-uniform steerer tube 100 inaccordance with one embodiment of the present invention. Referring stillto FIG. 1, in the present embodiment, non-uniform steerer tube 100includes an outer surface 102 (may also be referred to an outerdiameter) and an inner surface 104 (may also be referred to as an innerdiameter). In embodiments of the present invention, outer surface 102 isan axis-symmetric surface of revolution along the axial span (the “axialspan” may also be referred to herein as an “axial length”) ofnon-uniform steerer tube 100. That is, in various embodiments, outersurface 102 of non-uniform steerer tube 100 has a uniform diameter. Morespecifically, outer surface 102 has a uniform diameter length at anygiven location along the axial span of non-uniform steerer tube 100. Itshould be noted, however, that the uniform diameter length of outersurface 102 may be different at various locations along the axial spanof non-uniform steerer tube 100. For example, it can be seen from FIG.1, that the outer surface 102 of non-uniform steerer tube 100 has auniform diameter length, d, along span length portion 106 of non-uniformsteerer tube 100. It can further be seen from FIG. 1, that the outersurface 102 of non-uniform steerer tube 100 has a uniform diameter whichgradually decreases from a uniform diameter length, D, to a uniformdiameter length, d, along span length portion 108 of non-uniform steerertube 100 in the direction shown by arrow 110.

With reference still to FIG. 1, in embodiments of the present invention,inner surface 104 is not an axis-symmetric surface of revolution alongthe entire axial span of non-uniform steerer tube 100. That is, invarious embodiments, inner surface 104 of non-uniform steerer tube 100has a non-uniform diameter at, at least, one location along the axialspan of non-uniform steerer tube 100. Moreover, in embodiments of thepresent invention, inner surface 104 may have a non-uniform diameterlength at any given location along the axial span of non-uniform steerertube 100. Additionally, in embodiments of the present invention, innersurface 104 will have a non-uniform diameter length along the entireaxial span of non-uniform steerer tube 100. Also, in embodiments of thepresent invention, inner surface 104 will have a non-uniform diameterlength at multiple locations along the axial span of non-uniform steerertube 100. Furthermore, it should be noted, that in embodiments of thepresent invention, inner surface 104 may have a uniform diameter lengthat, at least, one location along the axial span of non-uniform steerertube 100.

Referring still to FIG. 1, it can be seen that at end 112 of non-uniformsteerer tube 100, inner surface 104 has a non-uniform diameter. Morespecifically, at end 112 of non-uniform steerer tube 100, inner surface104 has a non-uniform diameter which varies from a maximum length, L1,to a minimum length, L2.

Referring next to FIG. 2, a cross-sectional view of non-uniform steerertube 100 of FIG. 1 is provided in accordance with an embodiment of thepresent invention. The cross-section of FIG. 2 is taken at, or near, end112 of non-uniform steerer tube 100. FIG. 2 clearly shows thatnon-uniform steerer tube 100 has an inner surface 104 with a non-uniformdiameter which varies from a maximum length, L1, to a minimum length,L2. Thus, it can be stated that, in various embodiments, non-uniformsteerer tube 100 has a round outer profile but non-round inner profileat, at least, some location along the axial span of non-uniform steerertube 100.

With reference still to FIG. 2, in embodiments of the present invention,non-uniform steerer tube 100 will have an inner surface 104 which isoval in shape. In other embodiments of the present invention,non-uniform steerer tube 100 will have an inner surface 104 which isegg-shaped. In other embodiments of the present invention, non-uniformsteerer tube 100 will have an inner surface 104 which iselliptically-shaped. Additionally, in embodiments of the presentinvention, non-uniform steerer tube 100 will have an inner surface 104which is rectangularly-shaped. In various embodiments in whichnon-uniform steerer tube 100 has an inner surface 104 which isrectangularly-shaped, some of the embodiments have sides of differentthickness. Importantly, in embodiments of the present invention,regardless of the various examples of shapes and configurationsdescribed above, inner surface 104 of non-uniform steerer tube 100 has anon-uniform diameter at, at least, one location along the axial span ofnon-uniform steerer tube 100.

FIG. 3 provides another perspective view of non-uniform steerer tube 100taken from an angle different from that of FIG. 1.

FIGS. 4A-4C are side-sectional views of one embodiment of non-uniformsteerer tube 100, in accordance with an embodiment of the presentinvention. In the embodiment of FIGS. 4A-4C, inner surface 104 ofnon-uniform steerer tube 100 has a non-uniform diameter at section 2along the axial span of non-uniform steerer tube 100. Further, in theembodiment of FIGS. 4A-4C, inner surface 104 of non-uniform steerer tube100 has a uniform diameter at section 1 along the axial span ofnon-uniform steerer tube 100.

FIGS. 5A-5C are side-sectional views of another embodiment ofnon-uniform steerer tube 100, in accordance with an embodiment of thepresent invention. In the embodiment of FIGS. 5A-5C, inner surface 104of non-uniform steerer tube 100 has a non-uniform diameter at section 2along the axial span of non-uniform steerer tube 100. Further, in theembodiment of FIGS. 5A-5C, inner surface 104 of non-uniform steerer tube100 also has a non-uniform diameter at section 1 along the axial span ofnon-uniform steerer tube 100.

FIGS. 6A-6C are perspective views of a non-uniform steerer tube locatedon a bicycle, in accordance with an embodiment of the present invention.

In the various aforementioned embodiments of non-uniform steerer tube100, the “non-uniformity” of the diameter of inner surface 104 isselected to provide additional support for non-uniform steerer tube 100at locations thereof which are subjected to greater stress. If it isdetermined that a particular type of use is subjecting a steerer tube toa “fore and aft” force which is greater than a “side-to-side” force,embodiments of the present non-uniform steerer tube 100 will adjust thenon-uniformity of the diameter of inner surface 104 to provideadditional support with respect to the fore and aft force. Conversely,if it is determined that a particular type of use is subjecting asteerer tube to a “side-to-side” force which is greater than a “fore andaft” force, embodiments of the present non-uniform steerer tube 100 willadjust the non-uniformity of the diameter of inner surface 104 toprovide additional support with respect to the side-to-side force.

In embodiments of the present invention, when used with a vehicle,non-uniform steerer tube 100 will be oriented such that thenon-uniformity of the diameter of inner surface 104 provides additionalsupport with respect to an anticipated load. For example, in oneembodiment of the present invention, if it is anticipated that thevehicle will experience a fore and aft force/load, non-uniform steerertube is oriented such that the non-uniformity of the diameter of innersurface 104 of non-uniform steerer tube 100 will provide additionalsupport with respect to the fore and aft force.

As yet another example, in various embodiments of the presentnon-uniform steerer tube 100, the non-uniformity of the diameter ofinner surface 104 is adjusted to provide additional support at thebottom of non-uniform steerer tube 100. As yet another example, invarious embodiments of the present non-uniform steerer tube 100, thenon-uniformity of the diameter of inner surface 104 is adjusted toprovide additional support at the top of non-uniform steerer tube 100.As still another example, in various embodiments of the presentnon-uniform steerer tube 100, the non-uniformity of the diameter ofinner surface 104 is adjusted to provide additional support at both thetop and the bottom of non-uniform steerer tube 100.

Additionally, embodiments of the present non-uniform steerer tube 100adjust the non-uniformity of the diameter of inner surface 104 inresponse to various frequencies imparted to non-uniform steerer tube100. In one embodiment, non-uniform steerer tube 100 configures thenon-uniformity of the diameter of inner surface 104 such thatnon-uniform steerer tube 100 reduces and/or changes fore and aftvibrational and/or resonant frequencies. In another embodiment,non-uniform steerer tube 100 configures the non-uniformity of thediameter of inner surface 104 such that non-uniform steerer tube 100reduces and/or changes side-to-side vibrational and/or resonantfrequencies. In still another embodiment, non-uniform steerer tube 100configures the non-uniformity of the diameter of inner surface 104 suchthat non-uniform steerer tube 100 reduces and/or changes fore and aftand side-to-side vibrational and/or resonant frequencies.

As a result, embodiments of the present non-uniform steerer tube 100 areable to reduce and/or change the vibrations or other unwanted effectsimparted to a vehicle rider based on the conditions that the vehicleand/or non-uniform steerer tube 100 is experiencing.

In various embodiments of the present invention, non-uniform steerertube 100 “translates” the vibration that will be transferred to thehandlebars. That is, by adjusting the non-uniformity of the diameter ofinner surface 104, non-uniform steerer tube 100 alters the frequencies(makes the frequencies higher or lower) that are ultimately passed tothe vehicle user (via, e.g., the handlebars). It should be further notedthat in various embodiments, where it is desired to reduce the amplitudeof a particular frequency, non-uniform steerer tube 100 reduces thevibration that will be transferred to the handlebars by adjusting thenon-uniformity of the diameter of inner surface 104. Conversely, itshould be further noted that in various embodiments, where it is desiredto increase the amplitude of a particular frequency, non-uniform steerertube 100 amplifies the vibration that will be transferred to thehandlebars by adjusting the non-uniformity of the diameter of innersurface 104.

Although embodiments of the present non-uniform steerer tube explicitlydescribe adjusting the non-uniformity of the diameter of inner surface104, various other embodiments of the present invention adjust theresponse and operation of the steerer tube by varying the materialcomprising at least a portion of the steerer tube. It should further benoted that the present invention also includes embodiments is which thenon-uniformity of the diameter of inner surface 104 is adjusted, and thematerial comprising at least a portion of the non-uniform steered tubeis varied.

In embodiments of the present invention, outer surface 102 remainscircular (at each cross-section) along the span of non-uniform steerertube 100. Such a configuration has several advantages associatedtherewith, besides the advantages described above. For example, becausethe outer surface of non-uniform steerer tube 100 is not altered (i.e.,remains circular), non-uniform steerer tube 100 is still well suited touse with conventional bushings, gaskets, stems, and various othercomponents. As a result, the beneficial non-uniform steerer tube 100 ofthe present embodiments, can still be offered as an industry standardproduct.

Furthermore, as yet another benefit, as outer surface 102 remainscircular (at each cross-section) along the span of non-uniform steerertube 100, an observer viewing only the outer surface of non-uniformsteerer tube 100 would not be able to visually detect any differencebetween a conventional steerer tube and the present non-uniform steerertube 100. Hence, the beneficial features of the present non-uniformsteerer tube 100 are clandestine, and remain hidden to an observerviewing only the outer surface of non-uniform steerer tube 100.

Referring now to FIG. 7, a perspective view of a steerer tube 100coupled with fork assembly 700 is shown in accordance with anembodiment. In one embodiment, fork assembly 700 includes a crown 710,fork leg 720 a, and fork leg 720 b. An axle 730 is shown at the lowerportion of the fork assembly 700. The axle 730 would be placed throughthe center of a front wheel and about which the front wheel rotates. Inone embodiment, e.g., a duel legged fork setup, axle 730 is removablycoupled to fork leg 720 a and fork leg 720 b, thereby coupling the frontwheel to the fork assembly 700.

Although FIG. 7 shows the steerer tube 100 coupled with fork assembly700, in one embodiment, the steerer tube 100 could be coupled initiallyonly be coupled with crown 710 which would include opening(s) to allowfor the later addition of one or more of the fork legs. In oneembodiment, the forks leg(s) would be added at a later point in theassembly process. Thus, the steerer tube 100 would be aligned with thecrown 710 at the time of assembly. In one embodiment, one or both ofsteerer tube 100 and crown 710 could be composite, could be built as asingle composite, could be a single piece-metal form, or the like.

FIG. 8 is a perspective view of a steerer tube 100 coupled to a crown710 that includes an example alignment mark 810 in accordance with anembodiment. For example, during the assembly process, the alignment mark810 would allow the proper designated alignment during the assemblyprocess such that steerer tube 100 would be properly aligned with thecrown. Again, in one embodiment, the crown 710 and steerer tube 100would be aligned prior to the addition of the fork leg(s) to the crown.In another embodiment, the crown 710 and steerer tube 100 would bealigned after the addition of the fork leg(s) to the crown 710. In oneembodiment, steerer tube 100 could be circular, could have a lasermark,could be geometrically shaped other than round, or the like.

In one embodiment, the alignment mark 810 would be used when the steerertube 100 is non-uniform, when the steerer tube 100 is uniform, when thesteerer tube 100 is directional or includes a non-axisymmetric feature,and the like. For example, a directional or non-axisymmetric steerertube 100 could have a design that is uniform in exterior geometry butstructurally stronger in a defined direction. Thus, steerer tube 100would be mounted to the crown 710 in the orientation that allows theexpected direction of the largest forces applied to steerer tube 100,during a ride, to act in the same direction as the structurally strongerdefined direction of steerer tube 100.

FIG. 9 is a perspective view of the steerer tube 100 coupled to a crown710 that includes an alignment feature 910 along a portion of the lengthof steerer tube 100 in accordance with an embodiment. In one embodiment,alignment feature 910 is a male alignment feature, e.g., it protrudesfrom steerer tube 100 along a portion of the length of steerer tube 100.In one embodiment, alignment feature 910 is a female alignment feature,e.g., it is a channel or grove along a portion of the length of steerertube 100.

FIG. 10A is a perspective view of a stem 1000 with an alignment feature1020 in steerer tube receiver opening 1010 in accordance with anembodiment. In one embodiment, stem 1000 also includes a handlebaropening 1030 and an opening 1005. In general, handlebar opening 1030 isfor receiving and mechanically coupling one or more components of thehandlebars for the bike with one or more of the front end components,thereby allowing the rider to steer the bicycle.

In one embodiment, alignment feature 1020 is a female alignment feature,e.g., it is a channel or grove within steerer tube receiver opening1010. In one embodiment, alignment feature 1020 is a male alignmentfeature, e.g., it protrudes into steerer tube receiver opening 1010. Inone embodiment, opening 1005 could be used as part of a retaining designto allow stem 1000 to be tightened to steerer tube 100. In oneembodiment, opening 1005 could be a friction type retainingcharacteristic that allows the stem 1000 to be moved down a steerer tubewith an expanding radius until it is frictionally coupled. In oneembodiment, a fastener could be used in conjunction with opening 1005,the fastener allowing the stem 1000 to be moved down a steerer tube 100and then tightened to reduce the size of steerer tube receiver opening1010 and thereby couple the stem 1000 with the steerer tube 100.

FIG. 10B is a perspective view of a stem 1000 with an alignment feature1020 aligned with the alignment feature 910 of the steerer tube 100, inaccordance with an embodiment. In one embodiment, stem 1000 alsoincludes a handlebar opening 1030. In one embodiment, alignment feature1020 is a female alignment feature, e.g., it is a channel or grovewithin steerer tube receiver opening 1010. In one embodiment, alignmentfeature 910 of the steerer tube 100 is a male alignment feature, e.g.,it protrudes from steerer tube 100. Because of the alignment features1020 and 910, the stem 1000 be properly oriented with the steerer tube100 when the stem 1000 is mounted onto steerer tube 100. As statedabove, this alignment will ensure that the design characteristics ofsteerer tube 100 are properly aligned and oriented with respect to thehandlebar that will be held by stem 1000. This will allow theengineering features of the axisymmetric steerer tube 100 to be properlyoriented even if stem 1000 is installed or changed by a third party.

FIG. 11A is a perspective view of the steerer tube 100 coupled to acrown 710 that includes an alignment feature 910 along a portion of thelength of steerer tube 100 taken from an angle different from that ofFIG. 9, in accordance with an embodiment. In one embodiment, thealignment features 910 is a female alignment feature, e.g., it is achannel or grove along a portion of the length of steerer tube 100.

FIG. 11B is a perspective view of the stem 1000 with a female alignmentfeature 1020 aligned with the female alignment feature 910 of thesteerer tube 100 using a pin 1120 to align the two features (e.g., 1020and 910), in accordance with an embodiment. In one embodiment, by usinga separate pin 1120 to act as the aligning tool for the female versionsof both alignment feature 1020 of the stem 1000 and alignment feature910 of steerer tube 100, a number of advantages can be obtained. Forexample, the use of female alignment features in both parts will alloweither part to be used in legacy or non-aligned configurations

That is, one or more of the components could be used in an alignmentusage optional format. For example, if the user was upgrading parts,they could upgrade the stem 1000 to a stem with female alignmentfeatures 1020 while being able to continue using their legacynon-aligned-type steerer tube. Thus, one or more aligned componentscould be upgraded piecemeal, or the like.

In one embodiment, the usage optional factor could be a “directalignment” concept. For example, if both alignment feature 1020 of thestem 1000 and alignment feature 910 of steerer tube 100 are female, whenthe pin 1120 is not present, stem 1000 can be used on any steerer tube100, and any steerer tube 100 can be used with any stem 1000. Incontrast, when pin 1120 is present and in use, mechanical alignmentwould be required.

FIG. 12 is a perspective view of stem 100 coupled with steerer tube 100which is coupled with fork assembly 700 in accordance with anembodiment. In one embodiment, fork assembly 700 includes a crown 710,fork leg 720 a, and fork leg 720 b. An axle 730 is shown at the lowerportion of the fork assembly 700. The axle 730 would be placed throughthe center of a front wheel and about which the front wheel rotates. Inone embodiment, e.g., a duel legged fork setup, axle 730 is removablycoupled to fork leg 720 a and fork leg 720 b, thereby coupling the frontwheel to the fork assembly 700.

Keyed Headset Spacer

FIG. 13A is a perspective view of a keyed headset spacer 1300 with twoalignment features, in accordance with an embodiment. For example, keyedheadset spacer 1300 will have a first male alignment feature 1321 thatwill align with the female alignment feature 910 of steerer tube 100.Headset space 1300 will also have a second male alignment feature 1322that will align with the opening 1005 of stem 1000. Thus, when keyedheadset spacer 1300 is properly installed, stem 1000 will be properlyaligned with steerer tube 100.

FIG. 13B is a perspective view of the stem 1000 installed onto a steerertube 100, in accordance with an embodiment. In one embodiment, thesteerer tube has a female alignment feature 910 and the stem 1000 has noalignment feature 1020 but does have opening 1005. In anotherembodiment, stem 1000 includes a female alignment feature 1020 and alsoopening 1005.

FIG. 13C is a perspective view the keyed headset spacer 1300 of FIG. 13Aaligning the stem 1000 and the steerer tube 100 of FIG. 13B, inaccordance with an embodiment. In one embodiment, the first malealignment feature 1321 of keyed headset spacer 1300 will align with thefemale alignment feature 910 of steerer tube 100. In addition, thesecond male alignment feature 1322 of keyed headset spacer 1300 willalign with opening 1005 of stem 1000. As such, the proper installationof keyed headset spacer 1300 will cause stem 1000 to be properly alignedwith steerer tube 100.

In one embodiment, the use of the keyed headset spacer 1300 will provideanother usage optional factor, e.g., an “indirect alignment” concept.For example, as previously stated, if both alignment feature 1020 of thestem 1000 and alignment feature 910 of steerer tube 100 are female thestem 1000 and/or the steerer tube 100 could be used in a configurationthat did not include mechanical alignment. Moreover, when a normalheadset spacer is used, the stem 1000 and the steerer tube 100 couldstill be used outside of mechanical alignment. However, when the keyedheadset spacer 1300 is used, mechanical alignment between the stem 1000and the steerer tube 100 will be necessary to properly install the keyedheadset spacer 1300.

Top Cap

FIG. 14A is a perspective view of a top cap 1400 with two alignmentfeatures, in accordance with an embodiment. For example, top cap 1400will have a first male alignment feature 1421 that will align withininner surface 104 of steerer tube 100. As stated herein, in oneembodiment, inner surface 104 of non-uniform steerer tube 100 has anon-uniform diameter at, at least, one location along the axial span ofnon-uniform steerer tube 100. Thus, first male alignment feature 1421 oftop cap 1400 can be designed to directionally fit within the non-uniforminner surface 104 providing a predefined orientation between steerertube 100 and top cap 1400.

Top cap 1400 will also have a second male alignment feature 1422 thatwill align with an indent 1375 in keyed headset spacer 1300. Thus, whentop cap 1400 and keyed headset spacer 1300 are properly installed, stem1000 will be properly aligned with steerer tube 100 regardless ofwhether or not the non-round steerer tube 100 has an alignment feature910 and/or stem 1000 has an alignment feature 1020.

FIG. 14B is a perspective view of the stem 1000 installed onto a steerertube 100 in conjunction with keyed headset spacer 1300, in accordancewith an embodiment. In one embodiment, the stem 1000 does not have analignment feature 1020 and the steerer tube 100 does not have analignment feature 910. In one embodiment, the steerer tube 100 has afemale alignment feature 910 and the stem 1000 has no alignment feature1020 but does have opening 1005. In another embodiment, the steerer tube100 does not have an alignment feature 910 but the stem 1000 includesthe female alignment feature 1020 and also opening 1005. In yet anotherembodiment, the stem 1000 has alignment feature 1020 and the steerertube 100 has alignment feature 910. In one embodiment, the second malealignment feature 1322 of keyed headset spacer 1300 will align withopening 1005 of stem 1000. Further, in one embodiment, there is anindent 1375 on the top side of keyed headset spacer 1300.

FIG. 14C is a perspective view the top cap 1400 of FIG. 14A acting inconjunction with the keyed headset spacer 1300 to aligning the stem 1000and the steerer tube 100 of FIG. 14B, in accordance with an embodiment.In one embodiment, during installation, second male alignment feature1422 of top cap 1400 will align with indent 1375 in keyed headset spacer1300, while the first male alignment feature 1321 of keyed headsetspacer 1300 will also be aligned with opening 1005 of stem 1000. Inaddition, the first male alignment feature 1421 of top cap 1400 willdirectionally fit within the non-uniform inner surface 104 providing apredefined orientation between steerer tube 100 and top cap 1400. Assuch, the proper installation of top cap 1400 and keyed headset spacer1300 will cause stem 1000 to be properly aligned with steerer tube 100.

FIG. 14D is a sectional view FIG. 14C, where the top cap 1400 of FIG.14A acting in conjunction with the keyed headset spacer 1300 to aligningthe stem 1000 and the steerer tube 100 of FIG. 14B, in accordance withan embodiment.

In one embodiment, the use of top cap 1400 will provide another usageoptional factor, e.g., an “indirect alignment” concept. For example, aspreviously stated, if both alignment feature 1020 of the stem 1000 andalignment feature 910 of steerer tube 100 are female the stem 1000and/or the steerer tube 100 could be used in a configuration that didnot include mechanical alignment. Moreover, when a normal top cap isused, the stem 1000 and the steerer tube 100 could still be used outsideof mechanical alignment. However, when the top cap 1400 is properlyinstalled in conjunction with a keyed headset spacer 1300, mechanicalalignment between the stem 1000 and the steerer tube 100 will occur.Further, the top cap 1400 and keyed headset spacer 1300 can providemechanical alignment between the stem 1000 and the steerer tube 100regardless of whether steerer tube 100 has alignment feature 910 or stem1000 has alignment feature 1020.

The examples set forth herein were presented in order to best explain,to describe particular applications, and to thereby enable those skilledin the art to make and use embodiments of the described examples.However, those skilled in the art will recognize that the foregoingdescription and examples have been presented for the purposes ofillustration and example only. The description as set forth is notintended to be exhaustive or to limit the embodiments to the preciseform disclosed. Rather, the specific features and acts described aboveare disclosed as example forms of implementing the Claims.

Reference throughout this document to “one embodiment,” “certainembodiments,” “an embodiment,” “various embodiments,” “someembodiments,” “various embodiments”, or similar term, means that aparticular feature, structure, or characteristic described in connectionwith that embodiment is included in at least one embodiment. Thus, theappearances of such phrases in various places throughout thisspecification are not necessarily all referring to the same embodiment.Furthermore, the particular features, structures, or characteristics ofany embodiment may be combined in any suitable manner with one or moreother features, structures, or characteristics of one or more otherembodiments without limitation.

What is claimed is:
 1. A fork assembly comprising: a steerer tube; acrown, wherein said steerer tube is fixedly aligned to said crown in apredefined orientation at a time of manufacture; a male stem alignmentfeature on said steerer tube; and a stem to mount on said steerer tube,said stem comprising: a steerer tube receiver opening to allow said stemto mount on said steerer tube, and a female steerer tube alignmentfeature within said steerer tube receiver opening, an alignment of saidmale stem alignment feature with said female steerer tube alignmentfeature to ensure said stem is mounted to said steerer tube in apredefined orientation.
 2. The steerer tube of claim 1, wherein saidsteerer tube is orientationally structurally designed to provideadditional support for said steerer tube in at least one direction whichis subjected to greater stress during a use of said steerer tube.
 3. Thefork assembly of claim 2, further comprising: a steerer alignment markon said steerer tube, said steerer alignment mark based on saidorientational structural design of said steerer tube; and a crownalignment mark on said crown, wherein said steerer alignment mark isaligned with said crown alignment mark to obtain said predefinedorientation when said steerer tube is fixedly aligned to said crown atsaid time of manufacture.
 4. The fork assembly of claim 1, wherein saidsteerer tube and said crown are composite.
 5. The fork assembly of claim1, wherein said steerer tube further comprises: a non-axisymmetric innersurface, said non-axisymmetric inner surface has a non-uniform diameterlength at a location along an axial length of said steerer tube.
 6. Thesteerer tube of claim 5, wherein said non-axisymmetric inner surface hasa shape selected from a group consisting of: oval-shaped, egg-shaped,elliptically-shaped, rectangularly-shaped and some combination of saidshapes.
 7. A fork assembly comprising: a steerer tube orientationallystructurally designed to provide additional support for said steerertube in at least one direction which is subjected to greater stressduring a use of said steerer tube; a crown, wherein said steerer tube isfixedly aligned to said crown in a predefined orientation at a time ofmanufacture; a male stem alignment feature on said steerer tube; and astem to mount on said steerer tube, said stem comprising: a steerer tubereceiver opening to allow said stem to mount on said steerer tube, and afemale steerer tube alignment feature within said steerer tube receiveropening, an alignment of said male stem alignment feature with saidfemale steerer tube alignment feature to ensure said stem is mounted tosaid steerer tube in a predefined orientation.
 8. The fork assembly ofclaim 7, further comprising: a steerer alignment mark on said steerertube, said steerer alignment mark based on said orientational structuraldesign of said steerer tube; and a crown alignment mark on said crown,wherein said steerer alignment mark is aligned with said crown alignmentmark to obtain said predefined orientation when said steerer tube isfixedly aligned to said crown at said time of manufacture.
 9. The forkassembly of claim 7, wherein said steerer tube further comprises: anon-axisymmetric inner surface, said non-axisymmetric inner surface hasa non-uniform diameter length at a location along an axial length ofsaid steerer tube, said non-axisymmetric inner surface has a shapeselected from said group consisting of: oval-shaped, egg-shaped,elliptically-shaped, rectangularly-shaped and some combination of saidshapes.
 10. A fork assembly comprising: a steerer tube; a crown, whereinsaid steerer tube is fixedly aligned to said crown in a predefinedorientation at a time of manufacture; a female stem alignment feature onsaid steerer tube; a stem to mount on said steerer tube, said stemcomprising: a steerer tube receiver opening to allow said stem to mounton said steerer tube, and a female steerer tube alignment feature withinsaid steerer tube receiver opening; and a pin for insertion within anopening formed when said female stem alignment feature is properlyaligned with said steerer tube alignment feature, said inserted pin toproperly orient said stem with said steerer tube in a predefinedorientation.
 11. The steerer tube of claim 10, wherein said steerer tubeis orientationally structurally designed to provide additional supportfor said steerer tube in at least one direction which is subjected togreater stress during a use of said steerer tube.
 12. The fork assemblyof claim 11, further comprising: a steerer alignment mark on saidsteerer tube, said steerer alignment mark based on said orientationalstructural design of said steerer tube; and a crown alignment mark onsaid crown, wherein said steerer alignment mark is aligned with saidcrown alignment mark to obtain said predefined orientation when saidsteerer tube is fixedly aligned to said crown at said time ofmanufacture.
 13. The fork assembly of claim 10, wherein said steerertube and said crown are composite.
 14. The fork assembly of claim 10,wherein said steerer tube further comprises: a non-axisymmetric innersurface, said non-axisymmetric inner surface has a non-uniform diameterlength at a location along an axial length of said steerer tube.
 15. Thesteerer tube of claim 14, wherein said non-axisymmetric inner surfacehas a shape selected from a group consisting of: oval-shaped,egg-shaped, elliptically-shaped, rectangularly-shaped and somecombination of said shapes.
 16. A fork assembly comprising: a steerertube orientationally structurally designed to provide additional supportfor said steerer tube in at least one direction which is subjected togreater stress during a use of said steerer tube; a crown, wherein saidsteerer tube is fixedly aligned to said crown in a predefinedorientation at a time of manufacture; a female stem alignment feature onsaid steerer tube; a stem to mount on said steerer tube, said stemcomprising: a steerer tube receiver opening to allow said stem to mounton said steerer tube, and a female steerer tube alignment feature withinsaid steerer tube receiver opening; and a pin for insertion within anopening formed when said female stem alignment feature is properlyaligned with said steerer tube alignment feature, said inserted pin toproperly orient said stem with said steerer tube in a predefinedorientation.
 17. The fork assembly of claim 16, further comprising: asteerer alignment mark on said steerer tube, said steerer alignment markbased on said orientational structural design of said steerer tube; anda crown alignment mark on said crown, wherein said steerer alignmentmark is aligned with said crown alignment mark to obtain said predefinedorientation when said steerer tube is fixedly aligned to said crown atsaid time of manufacture.
 18. The fork assembly of claim 16, whereinsaid steerer tube further comprises: a non-axisymmetric inner surface,said non-axisymmetric inner surface has a non-uniform diameter length ata location along an axial length of said steerer tube, saidnon-axisymmetric inner surface has a shape selected from said groupconsisting of: oval-shaped, egg-shaped, elliptically-shaped,rectangularly-shaped and some combination of said shapes.